Stellar Industries builds product confidence through multi-phase structural testing with CIRAS, gaining data-driven insight to guide design decisions and prepare a new bolted bumper for market.
Company Overview
Stellar Industries is a 100% employee-owned manufacturer headquartered in Garner, Iowa. Founded in 1990, the company designs and builds service truck bodies, mechanic and tire service cranes, lube systems, and related work-truck equipment. While Stellar has expanded into national and global markets through innovation and strategic acquisitions, the company remains deeply rooted in its Iowa community and
workforce.
Situation
As part of its continued focus on product innovation, Stellar Industries set out to develop a new bolted bumper assembly for its Class 5 (20K) and Class 8 (90K) trucks. The goal was to give distributors and customers greater installation flexibility while maintaining the strength, durability, and reliability associated with Stellar’s welded bumper designs.
To move forward with confidence, Stellar sought independent, data-driven testing to confirm how bolted designs performed under real-world loading conditions and how they compared to welded construction across different capacity levels. Clear performance thresholds were essential for accurate product ratings, customer confidence, and future market growth.
Stellar partnered with CIRAS, part of Iowa State University, to access specialized structural testing expertise and facilities capable of supporting this level of evaluation.
Solution
Through CIRAS, Stellar was connected with the Iowa State University Structural Engineering Research Lab to design and execute a comprehensive, multi-phase testing program. CIRAS helped coordinate the engagement, align testing with Stellar’s product goals, and adapt the scope as new information emerged.
The project included structural testing of multiple bumper configurations under rated load, fatigue, and failure conditions. Data collection focused on load response, deflection, and strain to closely replicate real-world use. When bolted connection challenges surfaced during fatigue testing, CIRAS supported an iterative approach that allowed Stellar to modify designs, adjust fixtures, and continue testing rather than pause development.
A second phase of work expanded on the original effort, incorporating additional fixture adjustments, factory modifications to a bumper assembly, revised loading conditions, and further testing. CIRAS remained engaged throughout the process, helping Stellar navigate technical complexity and maintain progress toward validated results.
Results
The collaboration delivered both technical clarity and business value for Stellar Industries.
Testing provided clear, measurable insight into the performance differences between bolted and welded bumper designs. Results showed that bolted construction performs well across many applications, while welded designs remain necessary for higher-capacity, extreme-duty use. This understanding allowed Stellar to define performance thresholds and accurately rate its bumpers based on capacity and use case.
Using the data, Stellar approved the bolted design for pre-production and showcased it at multiple industry trade shows, strengthening confidence among distributors and customers. The new design also offers practical benefits, including simplified installation, expanded bolt-on accessory options, and greater flexibility for vehicle configurations.
From a business perspective, the project supported an estimated $77,000 investment in product development and helped protect approximately $1 million in projected annual sales tied to the bumper platform. Across both phases of work, the testing and design refinement efforts generated roughly $60,000 in documented project impact, reflecting the value of validation, iteration, and improved product readiness.
“CIRAS helped us validate our design with real data, giving our team and our customers greater confidence in the product’s performance,” said Tim Worman of product management at Stellar Industries.
“The testing support from CIRAS gave us the clarity we needed to finalize our design and move toward pre-production with confidence,” said Mitch Horstman of design engineering at Stellar Industries.
CIRAS, part of Iowa State University, helps Iowa companies solve complex challenges and move forward with confidence.
Contact John Roberts to learn more.